Conformable pod for a manual implement

ABSTRACT

A conformable pod and related method of production are provided, wherein the pod defines a soft structure adapted for deformation in response to minimal pressure applied manually, i.e., by contact with some portion of the body, and for retaining a deformed configuration substantially in the absence of continued application of manual pressure. The pod includes a viscous and tacky gel material encased within a closed chamber defined at least in part by a relatively thin and easily deformed outer skin providing minimal deformation resistance. In a preferred form, the encased gel material is a coagulated or partially coagulated gel such as a silicone-based gel material adapted for deformation in response to minimal applied pressure, and for substantially pressureless retention of the as-deformed shape, followed by relatively slow return (at least two seconds or more) to an initial nondeformed shape upon release of the pod.

BACKGROUND OF THE INVENTION

This invention relates generally to improvements in user contactsurfaces and related shape-conforming or biomorphic pods and grips foruse with manually grasped implements and the like, such as a cookingvessel, hair brush, paint brush, sports racquet or bat, scissors orother hand tool, musical instrument, or virtually any other type ofmanually grasped device having a handle or related structure for manualgrasping or engagement as by means of the hand or fingertips, oralternatively for contact and/or manipulation by a portion of the humanbody.

More specifically, this invention relates to an improved bioconformingor biomorphic pod for mounting onto an appropriate implement surface,and a related method of pod production, wherein the conformable podincorporates a viscous and tacky gel material adapted for custom-fitshape deformation in response to a minimal applied inertia or pressure,and for substantially pressureless retention of the deformed shape untilthe pod is released by the user. When released, the pod exhibits amemory characteristic for subsequent relatively slow return to aninitial nondeformed shape.

Manual implements generally incorporate a handle or related structurehaving a size and shape for appropriate manual grasping and manipulationof the implement during normal intended use. In one common form, thehandle structure comprises an elongated rigid element having one endsecurely connected to the implement, such as a cooking pot or pan, ahair brush, a tool head, etc. In another common form, the manualimplement is normally grasped directly about the body thereof, such asin the case of writing and other marking instruments, baseball andsoftball bats, etc. Other manual implements are adapted for fingertipmanipulation and thereby include one or more keypads for fingertipdepression, e.g., keyboards, musical instruments such as a clarinet,saxophone, trumpet and the like. Still other manual implementsincorporate handle-like structures of alternative or complex shapes,such as circular structures adapted for finger or fingertip insertion tomanipulation the implement, e.g., scissors and shears, and the like. Inthis regard, a variety of improved grips and the like have beendeveloped in recent years for use with such manual implements, primarilyto provide a relatively soft and resilient grip structure for enhanceduser comfort and/or improved control of the manual implement duringnormal use thereof.

In the past, grip structures for relatively large manual implements suchas sports equipment, hand tools, cookware, and hair brushes and the likehave generally been limited to relatively soft and resilient rubber orrubber-like elastomer sleeves or sleeve-like wraps mounted onto theimplement handle. While such grip structures beneficially provide adegree of cushioning for improved user comfort, the relative deformationof such grip structures during normal use is inherently limited. Inparticular, such cushioned grip structures are generally incapable ofsignificant shape deformation, and thus have generally not provided ahigh degree of shape deformation needed to assume a customizedergonomical shape conforming closely to the anatomical contours of anindividual user's hand and/or fingers. Such customized ergonomic shapeis beneficially conducive to substantially optimized user comfort withsubstantially minimized user fatigue, by providing anatomical pressurerelief while enhancing manual dexterity and improving manual control ofthe related device or implement.

In relatively small manual implements such as writing instruments andthe like, cushioned grip structures have been similarly provided in theform of resilient elastomer sleeves and the like. In some designs, anouter resilient sleeve encloses an internal cavity which is filled witha flowable substance such as a deformable putty or relatively viscousliquid adapted to displace and thereby achieve substantial shapedeformation when the grip structure is manually grasped. With suchdeformable grip structures, the outer resilient sleeve can exhibit arelatively high stiffness in comparison with the deformable putty orflowable substance contained within the internal cavity, whereby asignificant minimum applied pressure for grip deformation is defined bythe structure of the outer sleeve and not by the flowable materialcontained within said outer sleeve. In this regard, the structuralthickness and thus the stiffness of the outer sleeve is often increasedwith a view toward preventing or minimizing inadvertent sleeve punctureand resultant undesirable escape of the flowable material from theinternal cavity. Increased sleeve stiffness is, of course, contrary to adesire to provide a significantly reduced and substantially minimizedpressure threshold for initiating deformation of the deformable grip.Moreover, such grip structures having a flowable material encased withina resilient outer sleeve are difficult to manufacture and assemble.

Exemplary grip structures having a flowable material encased within anouter resilient sleeve or the like are shown and described in U.S. Pat.Nos. 5,000,599 and 6,647,582 and 6,725,505; U.S. Publication Nos.US2003/0123917; US2003/0051316; US 2004/0233169; and US 2004/0248063;and in copending U.S. Ser. Nos. 09/484,127, filed Jan. 15, 2000 and Ser.No. 10/678,148, filed Oct. 2, 2003.

There exists, therefore, a need for further improvements in and todeformable pods and grips of the type used with manual implements andthe like, particularly wherein a pod or grip structure can be initiallydeformed to a customized ergonomic shape upon application of anextremely light and substantially minimal pressure, and thereafterretain the deformed shape in substantial conformance with the uniqueanatomical contours of a specific user, substantially without requiringfurther or continued application of pressure, followed by relativelyslow return upon release of the pod or grip structure substantially toits initial non-deformed shape. The present invention fulfills theseneeds and provides further related advantages.

SUMMARY OF THE INVENTION

In accordance with the invention, a conformable or biomorphic pod andrelated method of production are provided, wherein the pod defines asoft structure adapted for mounting onto a user-contacted surface of amanual implement or the like, and for shape deformation in response tominimal pressure applied thereto, i.e., by contact with some portion ofthe body including but not limited to the fingers, fingertips, andhands, and for retaining a deformed configuration substantially in theabsence of continued application of manual pressure. The pod includes aviscous and tacky gel material encased or contained within a closedchamber or cavity defined at least in part by a relatively thin andeasily deformed outer skin providing minimal deformation resistance topod deformation and shape conformance to a substantially customizedergonomic shape conforming with the anatomical contours of theindividual user. In a preferred form, the encased gel material is acoagulated or partially coagulated gel such as a silicone-based gelmaterial adapted for deformation in response to minimal applied manualpressure, and for substantially pressureless retention of theas-deformed shape, followed by shape retention for a time delay periodfollowing user release (at least about two seconds or more) beforerelatively slow return (at least about four seconds or more) to aninitial nondeformed shape.

A fastener element such as a pressure sensitive adhesive film is carriedby the pod for stick-on attachment to a selected surface of a manualimplement or the like. In one alternative form, the fastener element maycomprise an elongated rim or rib carried by the pod and shaped forassembly as by clamped retention or the like between opposed structuresforming the manual implement or the like.

In the preferred form, the gel material comprises a coagulated orpartially coagulated or catalized gel or equivalent colloidal materialsuch as a silicone-based gel material adapted for deformation inresponse to minimal applied pressure. This gel material can berelatively tacky or sticky and thereby adheres to the chamber-defininginterior surfaces provided by the overlying pod skin. In one form, thehighly deformable pod skin cooperates with a rear-side substrate whichmay comprise a thicker, less deformable material, to define thegel-containing chamber or cavity. The fastener element may be formed onor as part of, or otherwise connected to the substrate.

In use, when the conformable pod is mounted onto a manual implement orthe like at a position for user contact during normal implement use, theouter skin is exposed for shape deformation in response to a relativelylight or minimal applied manual or tactile pressure or the like. Suchshape deformation of the outer skin is accompanied by a corresponding orconforming displacement of the gel material contained within the podcavity, wherein this gel material tends to retain the deformed shapeupon continued contact by the user but without requiring any significantcontinued application of manual or tactile pressure or the like.Thereafter, following user release of the pod, the gel material exhibitsa memory characteristic causing the pod to initially retain the deformedshape following user release for a time delay period of at least abouttwo seconds, and then return relatively slowly over a period of at leastabout four seconds to its initial nondeformed shape.

The conformable pod may be constructed by initially forming the outerskin as by injection, tumble, compression, or blow molding, or the like.The pod skin, in an inverted orientation, defines an open-sided chamberwhich is then substantially filled with the gel material, followed byclosing and sealing the pod chamber with the substrate.

In one preferred form and method, the skin may incorporate a texturedpattern and/or multiple folds in a corrugated configuration at one ormore locations or zones for further reducing the requisite tactile forceor the like required to deform the pod skin thereby displacing thecontained gel material within the enclosed chamber. In thisconstruction, the patterned or folded skin accommodates close controlover the timing and/or direction of skin and resultant overall poddisplacement. In a modified form, the patterned or folded skin zone orzones may each include a region of reduced or variable skin wallthickness. In each configuration, following user release, the gelmaterial encased by the skin returns slowly to an initial, substantiallynondeformed shape.

In one alternative preferred form, the deformable outer skin of theconformable pod can be shaped to define a plurality of elongated ribsformed generally in parallel relation and spaced apart by interveningtroughs or valley of substantial depth. This deformable outer skincooperates with a rear-side pod substrate which may comprises a thickerand/or less deformable material to define a closed chamber cavity thatis filled or substantially filled with the gel material. In one form,one or more fasteners such as mounting bolts are anchored as byco-molding within the rear-side pod substrate and protrude rearwardlytherefrom for quick and easy connection with an article or implementsuch as a chair structure, e.g., a chair seat or chair seatback. In use,a person sitting in the chair contacts the distal surfaces of theelongated ribs, resulting in displacement of the gel material within andbetween the pod ribs.

In one further alternative configuration, modified fasteners such asmechanical fasteners can be connected to a relatively stiff supportstrip formed from a suitable material and inserted as by co-moldingwithin the pod generally at an inboard side of the rear-side podsubstrate, with a portion of the fasteners protruding from or otherwiseexternally exposed at the rear side of the pod for mounting onto theselected article or implement. Alternative fasteners, e.g., magnet-typefasteners can be carried at the rear side of the pod for mounting ontothe selected article or implement. Alternative fastening methods canalso be used, such as co-molding of the selected article or implementdirectly to the rear side of the pod.

Other features and advantages of the present invention will become moreapparent from the following detailed description, taken in conjunctionwith the accompanying drawings which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

sFIG. 1 is a perspective view illustrating a conformable pod for usewith a manual implement or the like, constructed in accordance with thepresent invention;

FIG. 2 is an enlarged fragmented longitudinal sectional view takengenerally on the line 2-2 of FIG. 1;

FIG. 3 is an enlarged and fragmented sectional view illustrating aninitial process step for constructing the pod of FIGS. 1 and 2;

FIG. 4 is an enlarged and fragmented sectional view showing a subsequentprocess step for constructing the pod;

FIG. 5 is a enlarged and fragmented sectional view depicting a furtherprocess step for constructing the pod;

FIG. 6 is an enlarged and fragmented sectional view showing theconformable pod installed onto a user-contacted surface of a manualimplement or the like;

FIG. 7 is an enlarged and fragmented sectional view similar to FIG. 6,but illustrating pod deformation in response to a manual force or thelike applied thereto;

FIG. 8 is a fragmented perspective view of a plurality of conformablepods constructed in accordance with the present invention, and connectedend-to-end to define an elongated tape or the like adapted forinstallation onto a manual implement or the like;

FIG. 9 is an enlarged and fragmented sectional view similar to FIG. 6,but depicting one alternative preferred form of the invention;

FIG. 10 is an enlarged and fragmented sectional view similar to FIGS. 6and 9, but showing another alternative preferred form of the invention;

FIG. 11 is an enlarged and fragmented sectional view similar to FIGS. 6,9 and 1 0, but illustrating a further alternative preferred form of theinvention;

FIG. 12 is a side elevation view of a pair of scissors incorporating aconformable pod constructed in accordance with another alternativepreferred form of the invention;

FIG. 13 is an enlarged perspective view, show in partial section, of theconformable pod for use in the scissors depicted in FIG. 12;

FIG. 14 is an exploded perspective view showing installation of the podof FIG. 13 onto a pair of scissors;

FIG. 15 is an exploded perspective view similar to FIG. 14, but showingan alternative mounting arrangement for installing the conformable podonto a pair of scissors or the like;

FIG. 16 is a front perspective view of a chair including a plurality ofconformable pods mounted thereon;

FIG. 17 is an exploded perspective view of a portion of the chair shownin FIG. 16, and illustrating the multiple conformable pods in explodedrelation with a chair structure defining a chair seat and seatback;

FIG. 18 is a rear perspective view of one of the conformable pods shownin FIGS. 16 and 17;

FIG. 19 is an enlarged fragmented sectional view taken generally on theline 19-19 of FIG. 18;

FIG. 20 is an enlarged and partially exploded perspective view showingone preferred fastener for use in the conformable pod of FIGS. 16-19;

FIG. 21 is a perspective view of the fastener shown in FIG. 20; and

FIG. 22 is an enlarged fragmented sectional view illustrating connectionof the conformable pod of FIGS. 16-19 with the chair structure.

DETAILED DESCRIPTION OF THE PREFERRED EMOBIDMENTS

As shown in the exemplary drawings, an improved conformable orbiomorphic pod referred to generally in FIGS. 1-7 by the referencenumeral 10 is provided for use with a manually grasped implement 12(FIGS. 6-7) or the like. The conformable pod 10 is designed forplacement onto a user-contacted surface of the implement 12 where thepod flexibly and resiliently changes shape in response to a relativelysmall or lightweight applied pressure such as a manual or tactilefingertip pressure or other bodily contact during normal use of theimplement 12, so that the pod 10 deformably absorbs energy whileconforming geometrically to the unique and customized anatomicalcontours and particular grasping technique of an individual user. Theimproved pod 10 of the present invention further is designed to retainthe deformed shape upon continuity of manual grasping or bodily contact,but without requiring further application of manual pressure or the likethereto, in combination with memory characteristics for subsequentrelatively slow return to an initial nondeformed shape upon manualpressure release. As a result, the conformable pod 10 of the presentinvention provides anatomical pressure relief resulting in enhanced usercomfort and reduced user fatigue otherwise attributable, e.g., torepetitive motion or constant muscular exertion in the act of graspingthe pod in the course of implement manipulation. Such anatomicalpressure relief is beneficially accompanied by improved user dexterityand control of the implement 12.

The conformable pod 10 of the present invention may be used with a widerange of implements and devices designed or intended for contacting thehuman skin, particularly such as manually grasped implements includingbut not limited to items such as a cooking vessel, hair brush, paintbrush, scissors, sports racquet or bat, hand tool, musical instrument,or virtually any other type of manually grasped device having a handleor related structure for manual grasping or engagement as by means ofthe hand or fingertips. In this regard, it will be understood that useherein of the term manual implement will include devices that aregrasped, held, manipulated, or otherwise contacted by some portion of auser's body in the course of normal operation and/or use. Theconformable pod 10 may be constructed in a wide range of different sizesand shapes, or combination of multiple pods assembled for mounting as agroup, onto the handle structure or fingertip keypad structure or otherselected user-contacted surface of the related manual implement or thelike. In this regard, the pod 10 may be sized and shaped for mountingonto a flat surface, a curvilinear surface, or other geometric surfaces.In addition, the pod 10 may be construction in a cylindrical,sleeve-shaped configuration sized for slide-fit onto an implement handleor the like.

In accordance with a primary aspect of the invention, the conformablepod 10 incorporates a viscous and tacky gel or equivalent colloidalmaterial 14 adapted for resilient deformation when subjected to manualor other bodily pressure. This gel material 14 is contained within asubstantially closed chamber 16 defined at least in part by an outerskin 18 formed from a material, and having a thickness selected forminimal deformation resistance to applied lightweight manual or tactilepressure. Accordingly, the easily deformable skin 18 does not providesignificant resistance to pod deformation, thereby enabling the encasedgel material 14 to deform in response to minimal applied pressure.

Once deformed, the gel material 14 exhibits sufficient shape memorycapacity for relatively slow return to its initial nondeformed shapefollowing a time delay of at least about two seconds after release ofthe applied pressure. Accordingly, after deformation, the gel materialretains its deformed shape upon continued user contact, but in apressureless manner substantially without requiring further input ofmanual force or pressure to retain the pod 10 in the deformed shape.Following the post-release time delay, the gel material returns slowlyover a period of at least about four seconds or more substantially tothe initial nondeformed shape. In addition, in the event of inadvertentor accidental puncture of the outer skin 18, the gel material 14exhibits sufficient material integrity to prevent leakage outflow of thegel material from the pod interior.

As viewed in one preferred form in FIGS. 1 and 2, the conformable pod 10generally comprises an underlying substrate 20 of generally planarconfiguration, and which may be relatively thick, stiff, and/orresistant to easy deformation in comparison with the outer skin 18. Thissubstrate 20 is formed in a selected size and shape, such as theillustrative generally rectangular shape. A peripheral margin of thesubstrate layer 20 is joined as by suitable bonding with a peripherallower edge 22 of an upstanding perimeter side wall 24 formed as aportion of the overlying skin 18. This upstanding side wall 24 extendsupwardly from the substrate 20 and is joined at its upper end to a facewall 26. The assembled skin 18 (defined by the perimeter side wall 24and the face wall 26) and substrate 20 cooperatively define the enclosedcavity or chamber 16 filled with the deformable gel material 14. Afastener element 28 such as a film of pressure sensitive adhesive of thelike is carried at the underside of the substrate 20 for quick and easyaffixation of the assembled pod 10 onto a selected implement 12 (FIGS.6-7). FIG. 2 illustrates a peel-off liner 30 of paper-based material orthe like for exposing the fastener film 28 immediately prior to mountingof the conformable pod 10 onto the selected implement.

While the illustrative drawings show the conformable pod 10 to have agenerally rectangular shape, persons skilled in the art will understandthat numerous alternative pad configurations such as circular, oval,toroidal, cylindrical or sleeve-shaped, etc., may used. Moreover,persons skilled in the art will recognize and appreciate that othertypes of fastener elements may be employed, such as Velcro-type fastenercomponents, ribs or rims protruding from the substrate 20, and the like.

FIGS. 3-5 illustrate one preferred process for forming the conformablepod 10 of the present invention. As viewed in FIG. 3, the overlying skin18 may be formed as by an injection molding process or the like whereinflowable skin-forming material is injected under pressure as illustratedby arrow 32 into a mold cavity 34 defined between a pair of separableupper and lower male and female mold dies 36 and 38. In such moldingstep, the skin 18 is formed to have a selected overall size and shape,in combination with a selected, relatively thin wall thickness chosenfor easy deformation with little and virtually no resistance in responseto applied manual pressure. In one preferred form of the invention, theskin material comprises a thermoplastic resin such as a silicone-basedor polyurethane elastomer having soft structure (preferred durometer ofless than about 40-50 Shore A hardness), and preferably a thin wallthickness of the order of about 0.030 inch. As viewed in FIG. 3, thethus-molded skin 18 may include an integrally molded sprue 40 which iscut therefrom prior to subsequent process steps. Alternative productionprocesses such as tumble, compression, and blow molding will be apparentto persons skilled in the art.

The upper male mold die 36 is then separated from the lower female die38 having the molded skin 18 supported therein. In this configuration,the molded skin 18 is supported in an inverted orientation forfacilitated pour-in reception of the gel material 14, as illustrated byarrow 42 in FIG. 4. The molded skin 18 is substantially filled with thegel material, which preferably comprises a coagulated or partiallycoagulated or catalized gel such as a highly viscous and tacky siliconeor polyurethane gel material wherein the molecules are believed to beattached but not firmly held thereby permitting relative movement inresponse to applied manual pressure. Importantly, the tacky or stickycharacter of the gel material causes the gel to adhere or stickintimately with the inboard or underside surface of the inverted moldedskin 18, but substantially without fusing or conjoining of the gelmaterial 14 with the skin 18. With a molded skin 18 formed from asuitable silicon-based film material, it is believed that a molecularattraction between the skin 18 and the gel material 14, short ofmolecular bonding, effectively resists sliding displacement between theskin 18 and the gel 14 for enhanced pod displacement during use.

Exemplary gel materials include Silgel 612, available from WackerChemical Corporation, Adrian, Mich., and ER 8015 GE TSE3053, bothavailable from GE Silicones, Wilton, Mass. Importantly, such gelmaterials exhibit a memory characteristic whereby the materialdeformably responds to relatively lightweight or minimal appliedpressure, but thereafter, following a time delay of at least about twoseconds after user release, the gel material returns relatively slowly(over a period of at least five seconds or more) to its initialnondeformed shape. The gel material has a preferred penetration range ofabout 100-1,000 cm/sec., and preferably a precured viscosity range ofabout 500 cP (centepoids) to about 1,500 cP.

FIG. 5 shows a subsequent process step wherein the substrate 20 isformed as by pouring (as illustrated by arrow 44) a selected elastomersuch as a silicone-based or polyurethane material over the gel material14, to cooperatively form the enclosed chamber 16 having the gelmaterial sealingly encased therein. For this step, a containment die 46may be assembled with the lower mold die 38 to retain the thus-pouredliquid substrate-forming resin until it cures sufficiently in adhered,substantially sealed engagement with the peripheral edge 22 of the skin18. Then, the thus-assembled cushioned pad 10 can be removed from themold die 38 and suitably assembled with the fastener element 28, aspreviously described (FIG. 2). A shallow textured pattern 48 (FIG. 1)may be defined on the outboard surface of the face wall 26 to facilitatepod removal from the mold die 38, if desired.

FIG. 6 shows the conformable pod 10 of the present invention installedonto a selected manual implement 12, with the pod face wall 26 definedby the thin outer skin 18 presented outwardly for appropriate manual orfingertip contact or the like during use of the implement. FIG. 7 showsdeformable response to an applied force such as a manual or tactileforce depicted by arrow 50, namely, downward deformation of the thinouter skin 18 with minimal resistance for transferring the appliedmanual force to the gel material 14 contained within the enclosedchamber. As the gel material 14 deforms, the molecules thereof shiftabout within the chamber 18, and adhere to the inboard surfaces of theskin and substrate 18 and 20, while absorbing the applied energy. At thesame time, the outwardly presented geometry of the skin 18 deformablyconforms to the anatomical shape of the person's hand or fingertips orthe like in contact with therewith. The result is a highly comfortable,substantially custom-fitted interface between the person's hand orfingertips and the manual implement, thereby reducing friction,irritation, and user fatigue particularly such as fatigue and/or injuryassociated with and/or attributable to repetitive motion and/orcontinuity of applied manual force over an extended period of time.

In accordance with one important aspect of the invention, the gelmaterial 14 retains the deformed shape in a substantially pressurelessmanner, i.e., substantially without requiring the user to exert adeformation force for the purpose of holding and retaining the pod 10 inthe desired custom-fitted geometry. Instead, the user can operate and/ormanipulate the implement 12 in a secure, stable, and comfortable manner,without requiring continued exertion of additional forces to hold thepod 10 in the desired deformed shape. The gel material 14 maintains thedeformed shape for at least a short delay period following release ofthe applied pressure therefrom. That is, the gel material 14 tends toretain the deformed shape for at least about two seconds or more,following release of the applied pressure, and thereafter returns slowlyover a period of about four seconds or more to the initial nondeformedshape.

FIG. 8 shows one alternative form of the invention, wherein a pluralityof individually formed conformable pods 10 as previously shown anddescribed herein may be assembled as by means of a common substrate 20to form an enlarged or elongated deformable grip or the like formounting onto a selected manual implement or the like. Such enlarged orelongated deformable grip may be defined by interconnecting a single rowof multiple pods 10 formed end-to-end as shown to defined an elongatedtape-like structure adapted for wrapped installation, e.g., about thehandle of a manual implement, such as wrapping about the handle of agolf club, baseball or softball bat, or tennis racquet or the like.Alternatively, such tape-like structure may be constructed with multiplerows of interconnected pods 10 to form a wider structure adapted forwrapped or other suitable mounting onto a manual implement or the like.

Additional alternative preferred forms of the invention are depicted inFIGS. 9-11, wherein a modified conformable pod is constructed generallyas shown and described previously herein, but wherein the overlying skinis modified for further enhanced flexibility, i.e., further reducedresistance to deformation in response to a relatively small orlightweight applied pressure. FIG. 9 shows a modified face wall 126 ofthe conformable pod to incorporate an array of shallow corrugations 60designed to decrease resistance to deformation in response to an appliedforce as illustrated by arrow 62. FIG. 10 shows a modified side wall 124to incorporate an array of shallow corrugations 64 designed to decreaseresistance to deformation in response to an applied manual force asillustrated by arrow 66. FIG. 11 depicts a variation of FIG. 10, whereincorrugations 164 formed in a modified side wall 224 are associated witha variable wall thickness, i.e., the thickness of the side wall 224 isrelatively thicker and thus relatively stiffer near the point ofattachment with the substrate 20, whereas the thickness of the side wall224 progressively decreases and thus becomes thinner and more flexiblein a direction toward the associated face wall 226. With thisconstruction, the overall resistance of the skin layer to an appliedforce as illustrated by arrow 68 is reduced. Alternative skinconfigurations may be employed wherein a relatively thick skin layer mayincorporate an array or arrays of shallow grooves in virtually anypattern (as by molding or scoring) to accommodate enhanced flexibilityin response to an applied force.

FIGS. 12-16 depict a further alternative preferred form of the inventionincluding one or more modified conformable pods 110, wherein componentscorresponding structurally and/or functionally with those previouslyshown and described herein are identified by common reference numeralsincreased by 100. As shown, the modified pods 110 are constructed in asubstantially ring-shaped or closed loop geometry for mounting onto amanual implement or the like such as the illustrative pair of scissors70. In this regard, FIG. 12 shows a pair of pods 110 mounted on thescissors 70 for lining the inner diameter margins of closed loopopenings 72 and 74 provided in a pair of scissors handles 76 and 78 forfinger grasping and manipulation of a pair of scissors blades 80 and 82.The conformable pods 110 lining these openings 72, 74 thus provide softdeformable structures for used contact during normal scissors usage.

FIG. 13 shows the conformable pod 110 comprising a closed loop orring-shaped outer skin 118 having a generally circular cross sectionalshape to define an enclosed chamber 116 filled substantially with aflowable material such as a gel or gel-like material 114 preferablyexhibiting the deformation and memory characteristics describedpreviously herein with respect to FIGS. 1-11. The outer skin 118 isjoined to a substrate rim or rib 120 shown protruding generally radiallyoutwardly from the circumference or outer periphery of the ring-shapedskin 118. This substrate 120 may be constructed from the same materialas the skin 118, but with increased thickness, or from an alternativestiffer and/or harder material to provide a sturdy structure adapted forquick and easy mounting of the pod 110 onto the associated scissorshandles 76 or 78.

FIG. 14 shows the scissors handle 78 to be constructed from a pair ofinitially split-apart handle segments 78 a and 78 b adapted for assemblyas by snap-fit and adhesive mounting in face-to-face relation with theprotruding substrate rim 120 securely clamped therebetween. FIG. 15shows a variation in this mounting arrangement wherein a snap ring 84 isadditionally provided for seating and locking the substrate rim 120securely between the interfitting handle segments 78 a and 78 b. Ineither assembly technique, the deformable pod 110 defined by the gelmaterial 114 contained within the hollow skin ring 118 is positioned atthe inner periphery, or inner diametric edge, of the associated handleopening 72, 74 wherein it is contacted by the user and compliantlydeforms as previously described herein to provide the desired customizedergonomic shape. The peripheral rim 120 thus also functions as afastener element for use in mounting the pod 110 onto the selectedimplement, it being understood that the ring-shaped pod 110 can beinstalled onto other types of implements conducive to a closed loop podgeometry.

FIGS. 16-22 illustrate another alternative preferred form of theinvention including one or more modified conformable pods 310 and 310′,wherein components corresponding structurally and/or functionally withthose previously shown and described herein are identified by commonreference numerals increased by 200. As shown best in FIGS. 16 and 17,the modified pods 310 and 310′ are provided for mounting onto thesupport structure of a selected article or implement such as a chair300. Three of the modified pods 310 are shown mounted onto a front oruser-contacted side of a support structure 312 such as chair seatback,whereas the modified pod 310′ comprises a single and larger conformablepod shown mounted onto the top or user-contacted side of a supportstructure 312′ such as a chair seat.

More particularly, each of the seatback pods 310 comprises a pluralityof elongated raised ribs 86 extending generally in parallel andspaced-apart relation, and separated by intervening recessed troughs orvalleys 87. These seatback pods 310 are each shown mounted onto thechair seatback 312 with the ribs 86 and troughs 87 oriented to extendgenerally transversely or horizontally across the chair seatback. Threeof the seatback pods 312 are shown mounted onto the seatback 312 invertically spaced relation to each other. Persons skilled in the artwill appreciate, however, that each seatback pod 310 can be constructedwith any convenient number of elongated ribs 86 with interveningrecessed troughs 87. In this regard, the seat pod 310′ has a similarconstruction and is shown in the illustrative drawings with a largernumber of elongated raised ribs 86 with intervening recessed troughs orvalleys extending generally transversely across the chair seat 312′.

FIGS. 18-21 depict further construction details for one of the seatbackpods 310, but it will be understood that the seat pod 310′ has a similarconstruction. More specifically, the illustrative seatback pod 310includes an outer skin 318 constructed from a relatively thin and easilydeformed material (as previously shown and described herein with respectto FIGS. 1-15) to incorporate a desired front-side or user-contactedside shape, namely, the elongated raised ribs 86 separated by theintervening recessed troughs 87. This outer skin 318 defines a frontside of an internal chamber or cavity 316 (FIG. 19) that is filled orsubstantially filled with the viscous gel material 314, again aspreviously shown and described herein. A rear side of this chamber orcavity 316 is closed as by means of a rear-side substrate 320.

In accordance with one primary aspect of the embodiment shown in FIGS.16-21, modified fasteners 328 such as mounting bolts 88 are anchoredwithin the conformable pod 310 and protrude rearwardly from therear-side substrate 320 for quick and easy mounting of the pod 310 ontoa selected article or implement such as the chair seatback 312 or thelike. FIG. 18 shows these mounting bolts 88 protruding rearwardly fromthe rear-side substrate 320 in a predetermined array or pattern forquick and easy slide-fit reception rearwardly through pre-formed boltholes 89 (FIG. 17) formed in the chair seatback 312. A similar array ofbolt holes 89 is also formed in the chair seat 312′ for appropriatemounting of the seat pod 310′. Suitable nuts such as wing nuts 90 or thelike (FIG. 22) are provided for removably mounting the bolts 88 onto thestructure, i.e., onto the chair seatback 312.

Each of the mounting bolts 88 has a head portion 91 securely anchored tothe associated conformable pod. As viewed best in one preferred form inFIGS. 20-21, the bolt head portion 91 may comprise a threaded nut 92captured within a disk-shaped head housing 93 formed from a suitableplastic material, with one end of a threaded bolt shank 94 capturedwithin said nut 92. With this construction, the threaded bolt shank 94protrudes outwardly from one side of the disk-shaped head housing (FIG.21). This mounting bolt unit 88 is adapted for secure anchoredinstallation of the head portion 91 as by co-molding within a relativelystiff support strip or plate 95 (FIG. 19) disposed at a rear side of thepod. As shown, this support strip 95 may be co-molded within the pod,generally at an inboard side of the rear-side substrate 320 to provide astiff and stable base for the mounting bolts 88. In one preferred form,the support strip 95 comprises a layer of thicker and less deformablematerial in comparison with the outer skin 318, suitable for co-moldedembedment of the bolt head portions 91 therein. Alternatively, thesupport strip 95 may be formed from a rigid material, such as metal orplastic. As a further alternative, the support strip 95 may incorporateand comprise the rear-side substrate 320 of the conformable pod.

In use, when the conformable pods 310 or 310′ are mounted onto theappropriate article or implement such as the illustrative chair seatback312 or chair seat 312′, the user contacts the raised or distal endportions of the elongated ribs 86 resulting in deformation of the gelmaterial 314 contained therein. As shown best in FIGS. 19, the recessedtroughs or valleys 87 separating the raised ribs 86 are at leastslightly spaced from the rear-side substrate 320 and/or the supportstrip 95 so that the cavity-filling gel material 314 is present in acontinuum communicating within the closed chamber 316 between adjacentribs 86. Thus, the gel material 314 responds to user-applied pressure toconformably and deformably respond so that the ribs 86 collectivelycompress to assume a custom anatomical configuration. When theuser-applied pressure is released, the gel material 314 will slowlysubstantially to its original non-deformed shape, thereby returning thepod substantially to its original rib and trough configuration.

In further alternative form, different types of mechanical fasteners maybe employed, such as magnet fasteners carried by the conformable pod atthe rear side thereof for quick and easy attachment to the structure ofa selected article or implement. A magnet can be carried at a rear sideof the pod for attachment to a suitable structure which may include amating magnet of opposite polarity. Or, in some configurations, therear-side substrate of the conformable pod may be designed for directattachment as by co-molding directly onto the structure of the selectedarticle or substrate.

A variety of further modifications and improvements in and to theimproved conformable pod of the present invention will be apparent tothose persons skilled in the art. Accordingly, no limitation on theinvention is intended by way of the foregoing description andaccompanying drawings, except as set forth in the appended claims.

1. A conformable pod for mounting onto a user-contacted implement,comprising: a viscous gel material encased within a substantially closedchamber having a user-contacted front side defined at least in part by arelatively thin and easily deformable outer skin, and a rear-sidesubstrate; and at least one fastener carried by said rear-side substratefor mounting the pod onto a user-contacted implement, said fastenerbeing at least partially embedded within the pod; said outer skin andsaid gel material being deformable to a deformed shape in response toengagement with minimal applied manual pressure, and for substantiallypressureless retention of said deformed shape.
 2. The conformable pod ofclaim 1 further including a support strip disposed generally at the rearside of the pod, said support strip having a stiffness substantiallygreater than the stiffness of said outer skin, said at least onefastener being carried by said support strip.
 3. The conformable pod ofclaim 2 wherein said support strip is disposed within said chambergenerally at an inboard side of said rear-side substrate.
 4. Theconformable pod of claim 2 wherein said at least one fastener is atleast partially embedded within said support strip.
 5. The conformablepod of claim 1 wherein said rear-side substrate has a stiffnesssubstantially greater than the stiffness of said outer skin, said atleast one fastener being carried at least partially embedded within saidrear-side substrate.
 6. The conformable pod of claim 1 wherein said atleast one fastener comprises a plurality of fasteners.
 7. Theconformable pod of claim 1 wherein said at least one fastener comprisesa bolt protruding rearwardly from said rear-side substrate.
 8. Theconformable pod of claim 1 wherein said at least one fastener comprisesa magnet carried at the rear side of the pod.
 9. The conformable pod ofclaim 1 wherein said outer skin is shaped to define said closed chamberhaving a plurality of elongated raised ribs separated by interveningrecessed troughs, and wherein said troughs are spaced at least slightlyfrom said rear-side substrate.
 10. The conformable pod of claim 1wherein said gel material has a memory for retaining said deformed shapefor a predetermined time delay period following release thereof, and forthereafter returning relatively slowly following said time delay periodsubstantially to an initial nondeformed shape.
 11. The conformable podof claim 10 wherein said time delay period is at least about twoseconds, and wherein said gel material thereafter returns over at leastabout four seconds substantially to the initial nondeformed shape. 12.The conformable pod of claim 1 wherein said gel material comprises an atleast partially coagulated gel material.
 13. A conformable pod formounting onto a user-contacted implement, comprising: a viscous gelmaterial encased within a substantially closed chamber having auser-contacted front side defined at least in part by a relatively thinand easily deformable outer skin, and a rear-side substrate, said outerskin being shaped to define said closed chamber front side having aplurality of elongated raised ribs separated by intervening recessedtroughs, and wherein said troughs are spaced at least slightly from saidrear-side substrate, said gel material extending in a continuumsubstantially throughout said closed chamber; and at least one fastenercarried at least in part by said rear-side substrate and rearwardlyexposed for mounting the pod onto a user-contacted implement; said outerskin and said gel material being deformable to a deformed shape inresponse to engagement with minimal applied manual pressure, and forsubstantially pressureless retention of said deformed shape.
 14. Theconformable pod of claim 13 wherein said at least one fastener is atleast partially embedded within the pod.
 15. The conformable pod ofclaim 14 further including a support strip disposed generally at therear side of the pod, said support strip having a stiffnesssubstantially greater than the stiffness of said outer skin, said atleast one fastener being carried by said support strip.
 16. Theconformable pod of claim 14 wherein said rear-side substrate has astiffness substantially greater than the stiffness of said outer skin,said at least one fastener being carried at least partially embeddedwithin said rear-side substrate.
 17. The conformable pod of claim 13wherein said at least one fastener comprises a bolt protrudingrearwardly from said rear-side substrate.
 18. The conformable pod ofclaim 13 wherein said at least one fastener comprises a magnet carriedat the rear side of the pod.
 19. The conformable pod of claim 13 whereinsaid gel material has a memory for retaining said deformed shape for apredetermined time delay period following release thereof, and forthereafter returning relatively slowly following said time delay periodsubstantially to an initial nondeformed shape.
 20. The conformable podof claim 19 wherein said time delay period is at least about twoseconds, and wherein said gel material thereafter returns over at leastabout four seconds substantially to the initial nondeformed shape. 21.The conformable pod of claim 13 wherein said gel material comprises anat least partially coagulated gel material.